Laser Cutting Head Trajectory Partitioning for Corner Accuracy
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Solution Overview
Problem
Laser cutting devices face challenges in achieving high productivity and contour accuracy due to the limitations of mechanical axes dynamics, which result in reduced speed and increased time for cutting corners and small radii of workpieces, leading to undesirable contour errors and reduced cutting quality.
Innovation Solution
A device and method that utilize a high-frequency dynamic beam-shaping system to optimize the movement trajectory of the machining laser beam by redundantly partitioning it between the cutting head movement unit and the laser beam movement unit, allowing for reallocation of movement components and adjustment of parameters to compensate for deviations from the target contour, thereby improving cutting speed and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical axes are used to move the cutting head over the workpiece, then the laser beam can be directed to different positions, but the speed is reduced and time increases when cutting corners and small radii, leading to contour errors
Solution Approach 1:
The movement trajectory is segmented into two components: a low-frequency component handled by the mechanical cutting head movement unit and a high-frequency component handled by the dynamic laser beam movement unit. This segmentation allows each unit to operate within its optimal performance range, with the fast unit correcting trajectory deviations in real-time
Solution Approach 2:
The system transitions from static mechanical positioning to dynamic trajectory optimization by continuously adjusting the laser beam position at high frequencies (100 Hz to 10 kHz) to compensate for mechanical axis limitations, enabling real-time correction of contour errors during cutting
2Productivity
If the cutting head movement unit operates at high speed, then productivity increases, but contour errors increase at corners and small radii due to mechanical axis dynamics limitations
Solution Approach 1:
The control unit continuously monitors the movement trajectory and dynamically adjusts the laser beam position based on real-time feedback, compensating for deviations caused by mechanical axis limitations and maintaining contour accuracy even at high cutting speeds
Solution Approach 2:
The system replaces purely mechanical positioning with a hybrid approach where optical beam deflection substitutes for mechanical movement in the high-frequency domain, eliminating the need for mechanical axes to physically follow every contour detail
3Productivity
If rounding is applied to geometry or trajectory at corners and small radii, then mechanical axis speed can be maintained, but deviation from target contour increases
Solution Approach 1:
The control unit pre-calculates the optimal trajectory partitioning between mechanical and optical movement units, and the fast unit proactively compensates for expected contour deviations before they occur, maintaining both speed and precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances productivity and cutting quality by reducing contour errors, allowing for higher movement speeds at corners and small radii, and optimizing the movement trajectory to minimize deviations from the target contour, resulting in improved accuracy and reduced machining time.
Implementation Method 1
at least one dynamic laser beam movement unit (30) for producing a high frequency beam-shaping movement of the machining laser beam (24) at least perpendicular to its direction of propagation
Data Source
AI summary
Cutting a workpiece and producing workpiece parts are disclosed. The device has a cutting head with laser beam optics with a dynamic laser beam movement unit. A cutting head movement unit moves the laser beam over the workpiece. A control unit has a determination module to determine a movement trajectory of the laser beam, a memory unit from which at least one predetermined parameter selected from a movement parameter of the cutting head movement unit, a movement parameter of the laser beam movement unit and a parameter of a deviation of a cut contour from a predetermined contour is retrievable, and an optimization module for adjusting the movement trajectory by overlaying the movement of the laser beam via the cutting head with a high frequency beam-shaping movement of the laser beam via the laser beam movement unit based on the at least one predetermined parameter.